Subaru 2002 Impreza User manual

I
2002 IMPREZA SERVICE MANUAL
3
QUICK REFERENCEINDEX
GENERAL INFOMATION
SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully
to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement
of parts during
repair work is needed, be sure
to use
SUBARU genuine parts.
c- .
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIESLTD. G1830BE1

I

FOREWORD
FWa
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Page
Foreword .... .... ... ............. . .. ..... ... . ... .. ... ..... ... ........... .. ..... .. ....... . .... ...... ......... . .2
1 .

FOREWORD
FOREWORD
~
1. Foreword
A: FOREWORD
These manuals are usedwhen performing mainte-
nance,repairor diagnosisof the Subaru IMPREZA.
Applied model: GG*****and GD*****from
2001 MY.
The additional manuals below are also available:
AL (Pub. No. G0853ZE)
AUTOMATIC TRANSMISSION SERVICE MANU-
The manuals contain the latest information at the
time
of publication. Changes in the specifications,
methods,etc. may be made without notice.
FW-2

HOW TO USE THIS MANUALS
HU
Paae
--
1.
How to Use This Manuals ........................................................................... 2

I
HOW TO USETHIS MANUALS
HOW TO USE THIS MANUALS
1. How to Use This Manuals
A: HOW TO USE THIS MANUALS
1. STRUCTURE
Eachsectionconsistsof SCTthat are brokendown
into
SC that aredivided into sectionsfor eachcom-
ponent. The specification, maintenance and other
information for the components are included, and
the diagnosis information has also been added
where necessary.
2. INDEX
The first page has an index with tabs. And at the
end of each section is an alphabetical index.
3. COMPONENTS
For each component, a composition drawing is in-
cluded.
4. SPECIFICATIONS
ff necessary, specificationsare also included
5. INSPECTION
Inspections are included to be carried out before
and after maintenance.
6. MAINTENANCE
Maintenance instructions are provided for each
component. When multiple components comprise
one process, refer to the instructions for that pro-
cess for each component.
7. DIAGNOSIS
Tables showing a step-by-step process make it
easy to conduct diagnosis.
8. SI UNITS
Measurements in these manuals are according to
the
SI units. Metricand yard/pound measurements
are also included.
H U-2

SPECIFICATIONS
SPC
1 .
lmpreza ... . .. .. .. .. . . . . ... , ... .. .. . .. . . .. . . , . . .. ... , ... .. . ... . .. .. .. , . .. . . .. , . ... . .. . .. .. . . .. . . . .. . ... .. . .... .2
Page a

IMPREZA
SPECIFICATIONS
Model
1. lmpreza
A: DIMENSIONS
Sedan Waaon OUTBACK
Overallwidth mm (in)
Overall height (at CW) mm (in)
Compartment Length mm (in)
Width mm (in)
Overall lennth mm (in)
I 4,405 (173.4)
1,730(68.1) 1,695(66.7) 1,710(67.3)
1,465(57.7), 1,475(58.1),
1,485(58.5)*2 1,495(58.9)*2
1,440(56.7)
1,890(74.4) 1,845(72.6)
1,380(54.3)
Tread
I Front mm (in) I 1.485(58.5)
I Height
1.465(57.7) 1.460(57.5)
1,200(47.2), 1,200(47.2),
I 1,150(45.3)*3 I 1,150(45.3)*3
I 1 ,I 80 (46.5)
mm (in)
\I
Rear mm (in)
,\, .\, I\,
1,455(57.3) 1,455(57.3)
1,475(58.1
),
1,480(58.3)*1
Minimum road clearance mm (in) 160(6.3)
150(5.9), 150(5.9),
155 (6.1)*1 155 (6.1)*1
B: ENGINE
Model Turbo 2.0
L 2.5 L
I valve arranqement I Overheadcamshaft tvDe 1
Bore x Stroke mm (in)
Displacement cm3(cu in)
ComDressionratio
92
x 75
(3.62
x 2.95) 99.5
x 79.0
(3.917
x 3.1 IO)
1,994(121.67) 2,457
(1 49.9)
8.0
10.0
I Firinqorder I 1-3-2-4 -1
Maximumoutput kW (HP)/rpm 169(227)/6,000
Maximumtorque N.m (kgf-m,ft-lb)/rpm 294
(30.0, 217)/4,000
Idlespeedat Park/Neutral
I position(NCOFF) 123(165)/5,600
226 (23.0, 166)/4,000
rpm I
750 650 (MT)
700 (AT)
SPC-2

IMPREZA
SPECIFICATIONS
Model Turbo2.0 L
I
2.5 L
C: ELECTRICAL
Spark plug
Generator
Battery Type
Reservecapacity min
Coldcranking amp
amperes
CHAMPION: RCIOYC4(Standard)
NGK: PFR6G NGK: BKR5E-11
NGK: BKR6E-11
12V
- 90A
MT: 12V
- 48AH (55D23L)
AT: 12V
- 52AH (75D23L)
12V
- 75A
MT: 12V
- 48AH (55D23L)
AT: 12V
- 52AH (65D23L)
MT:99 MT: 99
AT:
111 AT: 118
MT:356 MT: 356
AT: 420 AT: 520
I I
MT: 1 O"k10°/650
AT: 1O"k10"/700
12"+10"/750
Ignitiontiming at idlingspeed BTDC/rpm
-'
Transmissiontype 5MTSrl 4ATlr2
Clutchtype DSPD TCC
Gear ratio
I 1st 3.454 2.785
rMm ~ I Turbo 2.0 L I
-
5th 0.738
Reverse 3.333 2.272
' Reductiongear 1 st reduction Type of gear
- Helical
Final reduction Type
of gear Hypoid Hypoid
, (Frontdrive) Gear ratio - 1.000
I I I Gear ratio I 3.900 I 4.1 11 I
Reductiongear
(Reardrive)
I L I I 4
Transfer reduction Type of gear Helical -
-
Gear ratio 1.100
Gear ratio 3.545 4.111
Final reduction Type
of gear Hypoid Hypoid
I 1 3rd I 1.366 I 1 .ooo I
I L I I
14th I 0.972 I 0.694 I
SPC-3

IM PREZA
SPECIFICATIONS
Model
Transmission type
Clutchtype
I
2.5 L
5MT*1 4ATlr2 5MTlrl 4AT*2
DSPD TCC DSPD TCC
RS Others
2nd
Reductiongear
(Reardrive)
r
2.062 1.619 2.062 1.545
I 1st
3rd
I 3.454 I 3.027 I 3.454 I 2.785 I
1.448 1 .ooo 1.448 1 .ooo
4th
5th
~~~
1.088 0.694 1.088 1.694
0.780
-
0.780 -
I Reverse I 3.333 I 2.272 I 3.333 I 2.272 1
1 st reductionReductiongear
(Front drive)
r
Dualrange - - - -
Type of gear - Helical - Helical
1 .ooo - 1 .ooo
Gear ratio -
Finalreduction
Transfer reduction
...
Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 4.1
11 4.444 3.900 4.1
11
Type of gear He
I ical
-
He I ical -
Finalreduction
I
5MTM : 5 forward speeds with synchromeshand I -reverse
4AT+2: Electronicallycontrolledfully-automatic,4-forwardspeedsand
1 -reverse
DSPD:Dry Single Plate Diaphragm
TCC: TorqueConverterClutch
E: STEERING
Gear ratio
1 .ooo
-
1.000 -
Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 4.1
11 4.444 3.900 4.1
11
Type
Turns, lock
to lock
Minimumturningcircle m
(ft) Curb to curb
Wall
to wall
I
Rack and Pinion
3.2 3
10.2 (33.5)
10.8 (35.4)
11 .I (36.3) 11.7 (38.3)
Front
Rear Macphersonstruttype, Independent,Coilspring
Dual-linkstrut type, Independent,Coilspring
Model
Service brake system
Front
H: TIRE
SEDAN WAGON
Dualcircuit hydraulicwith vacuum suspendedpowerunit
Ventilated disc brake
Rear
Parkingbrake Discbrake Drumbrake, Disc brakelrl
Mechanicalon rear brakes
SPC-4
Rimsize
Tire size
Type
15 x 6JJ 16
x 6’/2JJ
PI95/60R1587H P205/55R1689V
Steel belted radial,Tubeless

IMPREZA
SPECIFICATIONS
Fueltank Q (USgal, Impgal)
Engineoil Upper level
Q (USqt, Impqt)
Q (USqt, Impqt)
Lowerlevel
Transmissiongear oil
Q (US qt, Impqt)
I: CAPACITY
I
60 (15.9, 13.2)
4.5 (4.8, 4.0)
3.5 (3.7, 3.1)
60 (15.9, 13.2)
4.0 (4.2,3.5)
3.0 (3.2, 2.6)
-
3.5
-
3.5
(3.7,3.1) (3.7, 3.1)
Automatictransmissionfluid
AT differentialgear oil
AWD reardifferentialgear oil
Power steeringfluid
Enginecoolant
Q (USqt, Impqt)
Q (USqt, Impqt)
Q (USqt, Impqt)
Q (USqt, Impqt)
Q (USqt, Impqt)
I 5MT I 4AT I 5MT I 4AT I
9.5 (10.0, 8.4)
- 1.2 (1.3, 1.I) - 1.2(1.3, 1.1)
- 9.3 (9.8, 8.2) -
0.8 (0.8,0.6)
0.7(0.7,0.6)
7.7 (8.1, 6.8)
I 7.6 (8.0,6.7) I 7.0 (7.4, 6.2) 1 6.9 (7.3,6.1)
Turbo 2.0
L
WRX
5MTlrl 4ATJrl
2.5 L
RS
5MT 4AT
Model
t-
Curbweight (C.W.) Front kg(Ib)
Rear
ka (Ibl
I AWD I
826 (1,820) 851 (1,875) 778 (1,715) 803 (1,770)
569 (1.255) 569 (1.255) 567 (1.250) 567 (1,250)
Grossvehicle weight
(G
.V. W.) Front kg (Ib) 998 (2,200) 998 (2,200) 939 (2,070) 939 (2,070)
Rear kg(Ib) 857 (1,890) 857 (1,890) 857 (1,890) 857 (1,890)
Total kg(Ib) 1,837(4,050) 1,795(4,050) 1,778(3,920) 1,837 (4,050)
w. I1 .. I I. I I. .
I I
I
I I Total ka (Ib) I 1,395 (3,075) I 1,420(3,130) 1 1,345(2,965) I 1,370(3,020) I
SPC-5

IM PREZA
SPECIFICATIONS
Model
I
AWD
Xirbo 2.0
L
Curbweight (C.W.) Front kg (Ib)
Rear ka (Ib)
WRX
5MTt2 4ATt2
825 (1,820) 851 (1,875)
606 (1.335) 605 (1,335)
htai ka ob)
1 1,431(3,155) I 1,458(3,210)
~~
~
Grossvehicleweight
(G
. V. W. )
Front kg (Ib) 998 (2,200) 998 (2,200)
Rear kg (Ib) 925 (2,040) 925 (2,040)
Total kg (Ib) 1,901(4,190) 1,901 (4,190)
Curbweight (C.W.) Front kg(Ib)
Rear kg(Ib)
Total kg (Ib)
Grossvehicleweight Front kg (Ib)
-( G . v. w. ) Rear kg (Ib)
2.5
L
TS OUTBACK
-
5MTtl 4ATt 1 5MT 4AT
773 (1,705) 796 (1,755) 783 (1,725) 805 (1,775)
603 (1,330) 606 (1,335) 601 (1,325) 603 (1,330)
1,376(3,035) 1,402(3,090) 1,384(3,050) 1,408(3,l05)
939 (2,070) 939 (2,070) 939 (2,070) 939 (2,070)
925 (2,040) 925 (2,040) 925 (2,040) 925 (2,040)
-
Total kg(Ib) [ 1,833(4,040) I 1,833(4,040) I 1,833(4,040) I 1,833(4,040)
tl: Excludesweight of ABS, cruisecontrol.
t2:Excludesweight
of side air bag.
SPC-6

IMPREZA
SPECIFICATIONS
Turbo 2.0 L
I
2.5 L
2. CANADA SPEC. VEHICLE
Sedan
WRX
Model
RS
5MT 4AT 5MT 4AT
Curbweight
(C.W.)
Grossvehicleweight
(G
.V. W. )
Wagon
.-
*1: Excludesweight of air conditioner
Front kg (Ib) 826 (1,820) 851 (1,875) 778 (1,715) 803 (1,770)
Rear kg (Ib) 573 (1,265) 573 (1,265) 567 (1,250) 567 (1,250)
Total kg(Ib) 1,399(3,085) 1,424 (3,140) 1,345 (2,965) 1,370(3,020)
Front kg (Ib) 998 (2,200) 998 (2,200) 939 (2,070) 939 (2,070)
Rear kg (Ib) 857 (1,890) 857 (1,890) 857 (1,890) 857 (1,890)
Total kgOb) 1,837(4,050) 1,837 (4,050) 1,778 (3,920) 1,778 (3,920)
SPC-7

IMPREZA
SPECIFICATIONS
c- .
SPC-8

I
PRECAUTION
PC
Page
Precaution ........... .................. ...................................................................... 2
1 .

PRECAUTION
PRECAUTION
1. Precaution
A: PRECAUTION
Pleaseclearly understandandadheretothefollow-
ing general precautions. They must be strictly fol-
lowedto avoid minor or serious injury to the person
doing the work or people in the area.
1. ABS
Handle the ABS as a total system. Do not disas-
semble or attempt to repair individual parts. Doing
so could prevent the ABS system from operating
when needed or cause it to operate incorrectlyand
result in injury.
2. BRAKE FLUID
If brake fluid gets in your eyes or on your skin, do
the following:
Washout your eyesandseek immediatemedical
attention.
Wash your skin with soap and then rinse thor-
oughly with water.
3. ELECTRICFAN
The electric fan may rotate without warning, even
when the engine is not on. Do not placeyour hand,
cloth, tools or other items near the fan at any time.
4. ROADTESTS
Always conduct road tests in accordance with traf-
fic rules and regulations to avoid bodily injury and
interruptingtraffic.
5. AIRBAG
To prevent bodily injury from unexpected deploy-
mentof airbagsandunnecessarymaintenance,fol-
lowthe instructionsinthis manualwhen performing
maintenanceon the airbag components or nearby,
andthe airbag wiring harnesses or nearby.
To preventunexpecteddeployment,performoneof
the steps below and then wait at least
20 seconds
to discharge electricity before beginning work.
Step 1 : Turn the ignition switch OFF.
Step 2: Removethe negative battery terminal.
6. AIRBAG DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose the airbag modules in
the same way as other refuse. Follow instructions
of SOA (distributor) service for disposal of airbag
module. Follow all government regulations con-
cerningthe disposal of refuse.
7. AIRBAG MODULE
Adhere to the following when handing and storing
the airbag moduleto prevent bodily injuryfrom un-
expected deployment:
Do not holdthe harnessesor connectorsto carry
the module.
Do not face the bag in the direction that it opens
towards yourself or other people.
Do notface the bag in the direction that it opens
towards the floor or walls.
8. AIRBAG SPECIAL TOOLS
To prevent unexpected deployment, only use spe-
cial tools.
9. WINDOW
Always wear safety glasses when working around
any glass to prevent glass fragments from damag-
ing your eyes.
1O.WINDOWADHESIVE
Atways use the specified urethane adhesive when
attaching glass to prevent it from coming looseand
falling, resulting in accidents and injury.
PC-2

I
NOTE
NT
Page
1 . Note ............................................................................................................. 2

NOTE
NOTE
1. Note
A: NOTE
This is the information that can improve the effi-
ciencyof maintenanceandassurethe soundwork.
1. FASTENER NOTICE
Fastenersare usedto prevent the parts from dam-
age and dislocation due to looseness. Fasteners
must betightened to the specifiedtorque.
Donot apply paint, lubricant, rust retardantor other
substances to the surface around bolts, fasteners,
etc. Doing
so will make it difficult to obtain the cor-
recttorque and result in loosenessand other prob-
lems.
2. STATIC ELECTRICITYDAMAGE
Do not touch the ECM, connectors, logic boards
and other such parts when there is a risk of static
electricity.Always use a static electricityprevention
cord or touch grounded metal before conducting
work.
3. IGNITION OFF BATTERY
When removingthe battery cables, always be sure
to turn the ignition off to prevent electrical damage
to the
ECM from rush current.
4. SERVICEPARTS
Use authentic service parts for maximum perfor-
manceandmaintenance,whenconducting repairs.
Subaru/FHIwill not be responsiblefor poor perfor-
mance resultingfrom the use of parts not specified
by a genuine dealer.
NT-2

NOTE
NOTE
I
5. LIFTS AND JACKS
When using a lift or jack-ridged rack to raise a vehicle, always follow the instructions concerning jack-up
pointsand weight limits to preventthe vehicle from falling, which could result in injury. Be especially careful
to make sure the vehicle is balanced before raising it.
Support locations
A
Without side sill cover
I With-ver
Pantograph jack
fi.w
Lift
Safety stand
GI0166
NT-3

NOTE
NOTE
I
Front
nt cross member
Rear Rear differential
GI0121
NT-4